Jun 13, 2023     Canopy Fiberglassing       Category: Canopy+

I spent a few minutes cleaning up the fuselage and work area from the dirty job of sanding and filling which is now complete, until it comes time to paint the aircraft.

  Jun 12, 2023     Canopy Fiberglassing - (2.0 hours)       Category: Canopy+

Filled the few low spots and pinholes. Sanded them, reprimed the fairing. Any pinholes left (maybe one or two) will be taken care of when the plane is painted. Next is to remove most of the tape and all of the plastic protection, then move on. DONE!

  Jun 11, 2023     Canopy Fiberglassing - (1.5 hours)       Category: Canopy+

I sanded the last superfill application to a 220 grit finish. Then I masked off the area using paper taped around the fairing area and sprayed the Rust Oleum Filler Primer to the fairing area. It was a quick drying formulation so after about 5 minutes I removed the paper and masking tape. The finish wasn't perfect, darn it, as It did show a couple of areas needing a little more finish sanding and a few pinholes that will need attention. Other than that I'm pleased with the outcome. All the 'rough' spots and pinholes are easily manageable. The end is finally in sight.

  Jun 10, 2023     Canopy Fiberglassing - (1.0 hour)       Category: Canopy+

Now that the resin has dried, I sanded it down and found a few low spots that need more filler so I added superfill to those areas. For the record, that application of resin was excellent in highlighting the low spots. Although there were just a few of them, and it likely wouldn't have made a difference, now I expect the final result to be excellent with only pinholes to fill with the application of the filler primer. We'll see.

  Jun 09, 2023     Canopy Fiberglassing - (1.5 hours)       Category: Canopy+

Sanded the superfill from yesterday and used 220 grit to feather the forward edge - and the entire surface. Placed a sacrificial layer of masking tape all around the fairing and then applied a fairly heavy coat of resin. Once the resin was applied I waited a few minutes and removed the sacrificial layer of tape. Much to my surprise, everything is looking pretty good.

  Jun 08, 2023     Canopy Fiberglassing - (1.0 hour)       Category: Canopy+

Nearing the end. More sanding and just little filling. I believe this should do it. Next, I hope, it'll be ready for the final coat of resin and then the sanding filler. The end is in sight. All contours and flats are excellent. It'll look better when painted.

  Jun 07, 2023     Canopy Fiberglassing - (2.0 hours)       Category: Canopy+

Yep, you guessed it. More sanding and filling. I also removed the top layer of tape on the aft/canopy side, thus allowing more sanding lower to the canopy line. So overall it's looking pretty decent at this point. Just a few low spots then this could be the last major sanding before a coat of resin, sanding filler and finish sanding. Gotta get after those pinholes.

  Jun 06, 2023     Canopy Fiberglassing - (3.0 hours)       Category: Canopy+

Progress! More sanding, more filling. The contours, transition areas and flat areas are coming along nicely. I pulled the forward tape off and began to 'feather' the forward areas. It's looking a lot better, but it takes hours of sanding. I no longer have fingerprints as they've been sanded off with the 80 grit I've been using:-)

  Jun 05, 2023     Canopy Fiberglassing - (2.0 hours)       Category: Canopy+

Yep, more sanding, but this time I've added filler to the low spots and to the areas where the weave need filling. Progress.

  Jun 04, 2023     Canopy Fiberglassing - (1.0 hour)       Category: Canopy+

More sanding. Doesn't look like much progress, but there is. The contour is shaping nicely and the flat sides are almost there.

  Jun 03, 2023     Canopy Fiberglassing - (1.5 hours)       Category: Canopy+

Today, I began some serious sanding. The sides are very close to perfectly flat, but still need work. Then I began work on the 4 inch curvature area. This took a lot of effort - and I hardly made a dent. The curvature has many low spots but overall, not too bad and hopefully superfill should fix those. My concern revolves around the aft tape line. There are a lot of areas where the weave of the fabric shows lots of strands especially on the aft edge, again although it looks terrible superfill, should fix that. My major concern is to be sure I have smooth, even finish on the aft portion of the curvature. Note: I think the pictures accentuate the weave issue. At least I hope that's the case. I must say, the excellent Van's videos on the fiberglassing make it look sooo easy. Reality from an amateur is that the real world is very different.

  Jun 02, 2023     Canopy Fiberglassing - (1.0 hour) Category: Canopy+

With the fiberglassing 'done', I pulled the peel ply from the fuselage. The fiberglass didn't look too bad so I began sanding. After a short while I used the template and sure enough the curvature was pretty close but the sides needed much more sanding to get to 'flat'. Enough for the moment. I took a couple of hours to cleanup the shop from the fiberglassing and then called it a day.

  Jun 01, 2023     Canopy Fiberglassing - (5.0 hours)       Category: Canopy+

I was correct. Fiberglassing is an ugly nasty job! But it's done. Peel ply is on and waiting for the resin to cure. Except of course for the uglier nastier job of sanding and finishing. While it looks bad (my opinion) it does conform to the proper radius and flatness. At least I have that going for me. Can't wait to get back to metal working. Meanwhile, my engine has been completed by Thunderbolt and should arrive next week. Also, the final design of the panel was completed and I'm told it's being hot dipped this week. That means the airplane is 50% done with only 90% to go. Thought I would never get there.

  May 22, 2023     Canopy Fiberglassing - (2.0 hours)       Category: Canopy+

A quick correction to the taping as the forward tape does not get a sacrificial piece of tape over it. I solved the "problem" that was causing me such grief with the fiberglassing. I bought a new Fiskar 60mm circular cutter and now all is well, go figure. All the fiberglass pieces and peel ply pieces are cut. Wahoo! No pictures of the cut fiberglass - yet.

  May 21, 2023     Canopy Fiberglassing - (1.0 hour)       Category: Canopy+

After some thought I decided to redo the taping for the canopy. Since I'm using a black tint for the initial fiberglass layups I thought it would be better to use white electrical tape for the second layer. It'll be better to see and sand the fiberglass when that time comes. So I removed the top strip of black electrical tape, replaced it with white and redid the sacrificial masking tape layer as well as the tape holding the protective plastic down. The pictures show the evolution from white tape to sacrificial tape application and then when it's complete. It should be noted there's an extra strip of black electrical tape forward of the forward measured piece. I guess I'm paranoid about getting the resin on the airframe. Did the same on the aft piece of tape. Really paranoid about getting anything on the canopy.

  May 19, 2023     Canopy Fiberglassing - (2.0 hours)       Category: Canopy+

Did I mention I STILL hate fiberglassing!!!! My new and improved rotary cutter arrived so tomorrow I'll attempt to cut the fiberglass - again. However, today, I masked everything off, double taped, sacrificial taped and plastic protection for the fuselage are now all on and ready for the big fiberglassing day. Geez, the videos make it look so easy. Watched them yet again.

  May 11, 2023     Canopy Fiberglassing - (2.0 hours) Category: Canopy+

Yikes. After setting things up and trying to cut 1/4" strips of fiberglass, I gave up! I ended up going back to watching more videos on fiberglass basics - not Van's excellent videos that make it look too easy. It seems those little stripes want to unravel if you just look at them. Frustrating to say the the least. Stepping away and taking a short break seems to be the way to go for now.

  May 10, 2023     Research - (1.0 hour) Category: Canopy+

I watched Part 3 of the video for fiberglass application on the canopy. Probably one more review and I'll do the deed tomorrow, I hope.

  May 09, 2023     Canopy Fiberglassing - (1.0 hour)       Category: Canopy+

Mixed up a new batch of epoxy resin and micro balloons and filled a few of the voids in the first application. I also applied more void filler to the sides to meet the rather straight contour requirement. After I watch the videos again and a little more sanding on the aluminum and I'll be ready for the fiberglass application.

  May 04, 2023     Canopy Fiberglassing - (2.0 hours)       Category: Canopy+

I returned to the mess - I mean hangar, and it actually looked as bad as I thought it would. I started removing the excess filler with a razor blade then graduated to an electric sander and then a small sanding block. It actually came out sort of okay, but there were a few places that needed improvement. I repeated yesterday's debacle with about the same results - ugly mess. Hopefully sanding will fix it. At least I can sleep knowing this mess will never be seen again as it will be covered with a lot of fiberglass. I thought building a metal airplane would rid me of this exercise. - Hah!

  May 03, 2023     Canopy Fiberglassing - (1.5 hours)       Category: Canopy+

With the canopy secured in place it was time for void filling. I mixed the resin, black tint and hardener then added the micro balloons (cabo-sil) until the mixture was putty like and didn't flow. I placed it in the plastic baggie, clipped the corner open and spread it around. At this point I must say I HATE this portion of the build. Unlike the video where everything was neat and clean, mine was a freaking mess. Did I mention I HATE this! I left and let it dry.

  May 02, 2023     Canopy+ - (1.5 hours)       Category: Canopy+

I installed 5 clips to secure the windshield in place, although the fit was really good and three would have probably been okay. Better to be conservative here. I used a Dremel rotary cutter to 'sink' the clip to canopy level and not lie proud, but still had to slightly trim each clip to fit as close to level as possible.

  Apr 29, 2023     Canopy+ - (1.5 hours) Category: Canopy+

The hinge covers were checked and only a small snippet of sealant was trimmed back for all of the hinge covers to fit perfectly in place. The canopy was installed and locked in place on the fuselage. The weights were taped in place and all Zone 2 screws and nuts were tightened forward to aft then the weights were removed. Upon inspection the canopy appears to be sitting smoothly on the fuselage with very little bulging. The canopy clips were cut apart and if I can find my 1/8" dimple set the world would be nice. I'll keep looking!!!:-(

  Apr 27, 2023     Canopy+ - (2.0 hours)       Category: Canopy+

Completed the notching of the canopy seal and stowed it away for future use. Replaced the called out screws going thru the side skins and canopy with a slightly longer screw and now it's a much better fit. All the aft canopy screws were slightly tightened and the Zone 1 screws were rugged up. The left and right wear strips were fabricated and riveted in place. I did use a -5 length vice the called out 4.5 and again, it's a much better fit. There's no part of the rivet sticking out beyond water strip.

  Apr 25, 2023     Canopy+ - (2.0 hours)       Category: Canopy+

Continued notching the canopy seal and loosely installed the seal retainers on the canopy. Ran around searching for 2 slightly longer screws to fit where the left and right side frame attach screws go. I think the called out screw size is a little too short. More on this later. I also found that I don't have a small enough wrench to tighten the nuts on the screws. Off to Lowe's for a 3/16 socket or wrench.

  Apr 23, 2023     Canopy+ - (1.0 hour)       Category: Canopy+

After locating the 'missing' canopy seal I unwound it, clamped it down to the workbench with the C-01446 seal retainers on top and marked the hole locations. I test cut one of the notches and decided I better get a good exacto knife to do the rest of notching. Also, the attach screws were placed in all the remaining canopy holes and taped in place.

  Apr 22, 2023     Canopy+ - (3.0 hours)       Category: Canopy+

Today I arranged the canopy assembly to sit on 2 long boards so it could hang over the edge of the table so I could single handedly rivet the side skins and handles in place. Things went well until I aligned the pneumatic squeezer on the first rivet. It went to hell in about one second as the squeezer slipped off the rivet head while I was looking at the inside from underneath. In an instant I created a dent on the left side skin. So much for squeezing rivets on the side skins. It isn't that bad, but I should have known better. My friend Ron happened to stop by, took pity on me and volunteered to help. He's very mechanically inclined, but not airplane savvy, so I taught him how to handle the rivet gun while I bucked. It went well after that stupid initial mishap. So the side skins and handles are now riveted in place. A little body shop work later and that dent will be history. Stuff happens! Build on!!

  Apr 21, 2023     Canopy+ - (2.0 hours)       Category: Canopy+

After preparing the canopy (pulling back the protective plastic) for placement on the frame, Brenda and I placed the canopy on the frame and adjusted it to sit properly. Once done I inserted the shims inbetween the frame and plexiglass. On the left side, I ran the canopy lock wire thru the holes in the frame and alongside the canopy for hookup later in the build. Then I placed the side skins on each side; inserted the screws, washers and nuts on just finger tight and clecoed the skins and canopy handles in place. The rear of the canopy was temporarily clecoed to the aft frame.

  Apr 19, 2023     Canopy+ - (1.0 hour)       Category: Canopy+

Researched and gathered the parts for the canopy close switch and he defog fans. The fans were installed and the switch was loosely attached to the canopy frame but not wired at this time.

  Apr 17, 2023     Canopy+ - (2.5 hours)       Category: Canopy+

I needed to repair a few paint spots on the canopy frame and paint the rear window trim around the edges where the sealant will be. After clecoing the rear window in place, I masked off an outline where the window goes under the skin and then sealed off, with wide tape, the areas where the 'plastic' was, or could be exposed to the paint. After scuffing and cleaning the plastic edge the paint was sprayed on and when it became tacky I removed the outlining tape from the rear window.

  Apr 16, 2023     Canopy+ - (2.0 hours)       Category: Canopy+

I clecoed the side skins in place and my wife and I placed the canopy onto the frame. Once the weights were reattached I began doing the 80 grit sanding on the plexiglass and the fuselage. It took quite a bit of trimming and sanding to get the canopy to the right shape, and with no reflections, but it's done.

  Apr 15, 2023     Canopy+ - (3.0 hours)       Category: Canopy+

Completed double taping the forward trim/fairing and outboard lines on the canopy frame. I also cleaned the defog fan outlet holes of the paint build up from the spraying activity. Machine countersunk all the canopy attach holes. I believe all the canopy holes have been drilled - a big relief as I didn't cause any cracks in that high priced item.

  Apr 14, 2023     Canopy+ - (3.5 hours)       Category: Canopy+

I sanded off the mess I made with my attempts at glare shield painting by working my way from 100 to 600 grit. Then, with the help of my friend Ethan and his assistant Branden, we (Ethan) sprayed the glare shield and put on 3 beautiful coats of Ultra Matte Black. There were zero issues with the spray, no bursts or bubbles. I give him full credit for a job well done. There are just one or two areas that need interior gray paint due to the tape pulling it up. I'll catch those later. After the paint had dried a little, I outlined the side templates on the fuselage.

  Apr 13, 2023     Canopy+ - (1.0 hour)       Category: Canopy+

I moved the canopy frame outside and began painting the glare shield with Universal Advanced Formula Rust Oleum Flat Back. The first few swipes across the glare shield went well, but then the rattle can began spurting a few bubbles and leaking profusely all over my hand. I took the frame inside to let let it dry, went the store and bought a couple more cans of paint. I then sanded the glare shield, cleaned it, took outside again and began repainting. Things got worse and more 'massive spurting' of the paint began again. I know I suck as a painter, but this was supposed to be a simple spray job. A friend came by and said, "let me give it a try tomorrow with the paint I used on my motorcycle". Done! Sorry, while the pictures of the glare shield were too terrible to post I did post the errant can of paint. I hope someday my newly painted hands and black finger nail polish paint will come off. I got drenched in black.

  Apr 12, 2023     Canopy+ - (3.0 hours)       Category: Canopy+

I began prepping the canopy for the fiberglass installation by peeling back the protective plastic, lightly etching a line on the canopy @ 7/8", taping it off with a couple layers of electrical tape, then marked the fuselage's forward fairing line 2 inches from the aft fairing line and taped that line for future fiberglass fairing installation. We then removed the canopy assembly from the fuselage. The canopy was 'de-clecoed' from the frame and set side. The inside skins on the frame and the shims were deburred. The glare shield was scuffed for flat black painting and the entire frame was wrapped in paper, plastic and tape to prevent over spraying the black onto the interior finish. When the wind dies down I'll get that baby outside and painted.

  Apr 11, 2023     Canopy+ - (2.5 hours)       Category: Canopy+

I removed the canopy side skins and final-drilled the common canopy holes to #27, deburred them, re-clecoed them and final-drilled to #27 every hole common to the canopy and canopy frame assembly and also reclecoed them as I did this. There's was a lot of freaking clecoing going on today. Finally, I outlined the forward edge of the canopy as a guide for painting the glareshield. For what's it worth: I used a plexiglass #27 for drilling thru the canopy then I switched to regular #27 to drill thru the metal. I guess I could've used the plexiglass bit for everything, but I didn't want to ruin the bit for going thru plexiglass. If I missed a metal shaving that got stuck in the bit it could've ended up in the plexiglass and ripped the hole OR maybe it wouldn't have made a difference. I wasn't sure sure so I switched drills/bits each time.

  Apr 10, 2023     Research - (1.0 hour) Category: Canopy+

Searched for the 24x36 template for the fiberglass fairing pieces. No joy. Called Van's and they're mailing one out.

  Apr 08, 2023     Canopy+ - (3.0 hours)       Category: Canopy+

Now that the canopy is in place, the side shims installed and verified properly in place (again), the aft frame properly clamped to the roll bar and the canopy weighted down, it's time to begin drilling. My buddy Dean was inside the aircraft drilling the top few holes on the canopy/aft frame and clecoing them in place. I then started drilling, as per the directions, alternating on the left and right side skins and the left and right sides of the aft frame. Dean backed the drilling with a wood block against the inside side skin. When we finished, there were no bubbles or canopy movement. Chalk this one up to DONE! Couple of hints: I used a plexiglass #40 bit until I touched the side canopy shim then switched to a regular #40 bit. Also, we used a light shining up the hole on the aft frame to help locate the center of the hole in the canopy. This worked like a charm.

  Apr 07, 2023     Canopy+ - (3.0 hours)       Category: Canopy+

Trimmed the canopy from point Oscar forward leaving 3/32" width on the canopy bottom. Then we placed the canopy on the frame, centered it and using the forward and aft centerlines plus the forward line on the drawing, we verified the canopy fit with the 1/32" forward of the window shim on the aft frame. We checked the bottom of the canopy and it rests just above the tangent point, however it needed the C-01423 shim on each side. Then we clecoed the outside skin on each side. With that done I taped the weights on the forward part of the canopy. All looks good. While it's a little high *about 1/6" at most, in a couple of areas, a little finger pressure on the high spots places the canopy in a good position and it easily touched the canopy skin.

  Apr 06, 2023     Canopy+ - (2.5 hours)       Category: Canopy+

After trimming to the line, we placed the canopy on the frame, recentered it, retaped the aft edge and once again trimmed for the final fit. I had to take off another 1/32" or less and did so. The trimming is complete (I hope). I also marked the 3" line from point Oscar forward for trimming tomorrow.

  Apr 05, 2023     Canopy+ - (2.0 hours)       Category: Canopy+

So far so good. Still trimming away on the aft side of the canopy, but the end is in sight as I near the blue line. About 1/16" - 1/32" to go.

  Apr 04, 2023     Canopy+ - (1.0 hour)       Category: Canopy+

Trimming continues. Necessary, but boring. Regardless, progress is made as I get closer (slowly) to the finish line (pun intended.)

  Apr 03, 2023     Canopy+ - (2.0 hours)       Category: Canopy+

With the canopy removed from the aircraft and placed on the worktable, the trimming began. Yep, it's going to take a few hours, using a paint scrapper, although others have suggested using an electric sander, I'm not comfortable using that type of device on this expensive piece of 'plastic.'

  Apr 02, 2023     The Canopy - (2.0 hours)       Category: Canopy+

Peeled back the plastic covering, about a 1/4" on the inside of the canopy. Then lifted it onto the canopy frame, adjusted it so that it was on the forward canopy line of the drawing taped to the canopy frame. Then it was time to center it, which we did withe blue snapped line and triangle. Two 4" lines, fore and aft were drawn on the plastic covering. I then taped the aft portion of the canopy for trimming at the the required 1/32" forward of the rear window shim.

  Mar 30, 2023     Rear Window - (2.0 hours)       Category: Canopy+

Today I fabricated two separate #6 dimple die holders, one for the roll bar and stiffener skin hole and the other for the rear center hole. For the stiffener area hole the receiving die wouldn't fit so I made one out of hard wood that would fit between the skin and roll bar. The dimple die was placed into a piece of a wood and a 6" C clamp was used to squeeze the die together. With a little tweaking here and there the dimpled holes came out fine. For the rear center hole I used a 3" long piece of wood with a hole in it for the inside die while the other die was inserted into the wood piece I used for the stiffener area. Using the C Clamp, the dimple was formed. Job done. No rivets were hurt in this process:-)

  Mar 29, 2023     Rear Window - (3.0 hours)       Category: Canopy+

I reinstalled the rear window by installing the appropriate screws and placed a few clecoes around the side skins for support while I tape marked the excess material for removal. I then removed the rear window and used a razor blade paint removal tool to scrape off the excess material. I then used the tool to trim a 1/64th bevel around all sides of the window, inside and out. Fine sandpaper was used to remove the very few scratch marks that were left. Finally I dimpled almost all the skin window holes with a #6 dimple die. 3 holes remain to complete the task, the top center and two forward side holes, to be done later.

  Mar 27, 2023     Rear Window - (.5 hour) Category: Canopy+

I drilled and tapped the lower roll bar holes on each side and drilled #27 all the side window holes.

  Mar 26, 2023     Rear Window - (2.0 hours)       Category: Canopy+

Countersunk all the window holes for either the skin or attachment to the roll bar. I then 'broke' the edges of the skin where the window will attach. As discussed a couple of days ago, I couldn't break the edge where it's attached to the stiffener angle, but a long nose pliers did the job. Note to self: there is no good way to break the edge on the center skins. Just not enough clearance between the skin and center beam to get the tool in there. I either missed the callout to do this earlier or I'm missing tool the that could do the job. NOTE to builders who are actually reading this: The skin countersinks are not very deep, but the roll bar countersinks are quite deep. Also, use caution when countersinking on areas where the window bends sharply. It's easy to over do it. Hopefully better pictures later. This one shows how minor the countersinks are where they butt up to the skin.

  Mar 25, 2023     Rear Window - (2.0 hours)       Category: Canopy+

100% of the #40 window holes are now drilled. All the roll bar holes are now drilled to #36 and have been tapped for a #6 screw. I have opted to not tap the plexiglass rear window roll bar holes. I believe this will allow the rear window to slightly expand and contract with the OAT without bending/bubbling/cracking. I'll take slight comfort knowing other have successfully done it this way. All window holes have also been opened up to #27. I used Frog Tape - 'delicate' (and somewhat expensive) to hold back the plastic covering. The reason for 'delicate' is that I expect the tape to be on the window for a somewhat extended time, not the two days as Van's has listed. I will be checking on it though. If it works, I'll also use this tape for edging when painting the plastic over the roll bar and around the lower edges of the windows.

  Mar 23, 2023     Rear Window - (3.0 hours)       Category: Canopy+

Much progress made, especially with the assistance of my good friend Dean. A little more trimming over the stiffener bracket and now 98% of the #40 holes are drilled (actually hole locations 1-8 on the drawing are complete) but I had to call it a day due to other priorities. The most time consuming portion is simply getting the drill properly aligned because of its criticality in order to lay the window flat. Thus, the window lies perfectly flat, especially over the roll bar. This a testament to taking time to align and trim everything per the instructions and also to Van's precise manufacturing. Love it when a plan comes together:-)

  Mar 22, 2023     Rear Window - (3.0 hours)       Category: Canopy+

After closely re-reading the directions I decided to hold off on the canopy installation and backup to the rear window installation. While not really necessary, I though it prudent to fit the rear window first so that as I progress on the canopy installation and come to the trimming of the aft portion, the rear window is in place since it appears the canopy relies on the forward portion of the rear window for a trim line. Thus, with Dean's help we did the initial trimming of the aft portion of the window where if butts up against the roll bar brace. There's also another area to trim on the lower forward and bottom edge of the window where it sits just above the rivet stiffener angles and side skin attach areas. NOTE: It's just my opinion, but I had not installed these earlier, this would have been much more difficult and I would have still had to trim the window. Here's an additional note, a couple of days later. Maybe installing later would have been okay. It's a trade off, but breaking the edge of the skin over the bracket is almost impossible once riveted in place - not big deal, but not up to drawing. Oh well, time to move on. Also, I would have thought this to be 30 minute task, not a 3 hour task. Go figure.

  Mar 06, 2023     Canopy Frame - (.5 hour)       Category: Canopy+

With the outstanding help of my wonderful wife I completed riveting the canopy rails to the canopy assembly with the AN470-4-4 rivets.

  Mar 05, 2023     Canopy Frame - (1.0 hour)       Category: Canopy+

Riveted the canopy rails and shims to the canopy assembly - except for the rivets where the mid frame canopy fixture is attached.

  Mar 04, 2023     Canopy Frame - (3.0 hours)       Category: Canopy+

I spent the better part of the morning prepping portions of the frame for future painting, I then clecoed the aft frame parts to the forward frame in preparation for riveting.

  Mar 03, 2023     Canopy Frame - (2.0 hours)       Category: Canopy+

Riveted all the AN470AD3-4 rivets in the closeout frame. I tried using 3 different squeezers/frames with no luck due to the closeness of the skins and the splice rivets. Oh well, ended up bucking them all. Pretty close quarter on the ends, but they're all in and with no frame twist. Finished the day with installing the CS4-4 rivets on the end flange. Progress!

  Mar 02, 2023     Canopy Frame - (2.0 hours)       Category: Canopy+

Final drilled each of the #30 holes as called out for the frame close out plate and riveted them in place using the LP4-3 rivets as called out. I did the 'every 4 rivet check' for frame twist and fortunately thru skill (ha) and luck (yes) there was no twisting movement. I did have to modify a rivet squeezer to get to the rivets around the hinges, but other than that, everything went smoothly - albeit slowly.

  Mar 01, 2023     Canopy Frame - (3.0 hours)       Category: Canopy+

Completed riveting the left and right aft support frame to the canopy skin and the aft flanges to the intercostals. All three splice plates are now riveted in place. I adjusted the forward portion of the frame so the canopy fixture clecoes go in without any trouble. About 1/32" was all that was needed. The canopy frame closeout step 2 holes were final drilled to #30 and every hole remained clecoed after they were drilled. Then I checked for twist and the left and right frames remain within .1 degrees of each other. So far so good.

  Feb 28, 2023     Canopy Frame - (1.5 hours)       Category: Canopy+

Completed riveting the left and right canopy rails to the canopy skin. Before and after pictures tell the tale. Obviously I need to polish the face of the rivet gun as it's leaving too many dirty marks that make it look like a nasty job:-)

  Feb 27, 2023     Canopy Frame - (3.0 hours)       Category: Canopy+

My good friend Dean and I riveted the front two frames (left and right) and the left front rail to the canopy skin. Much better results than my failed back-riveting attempt yesterday.

  Feb 26, 2023     Canopy Frame - (1.0 hour)       Category: Canopy+

Moving on from my disastrous experiment yesterday, I successfully drilled out the messed up rivets. Then I rearranged all the clecoes for normal riveting with a bucking bar.

  Feb 25, 2023     Canopy Frame - (1.0 hour) Category: Canopy+

I had decided to back rivet the canopy skin to the frame. I set up everything to do this. My plan was to use an offset flat rivet set. Bad choice!!!! The flat rivet set has a tendency to push the rivet in a direction that is NOT straight down. I tried 4 or 5 times, changed the angle of the set each time and also changed how I held it hoping to change the forces' direction, but with no success. Personally, I don't recommend this technique, but I wish you luck and if you're successful - let others know how to do it. Update: After more thought (yes, it's bugging me), I believe this could be accomplished but it would require a flat offset head with very tight bends that would make the force go straight down. Where there's plenty of room for the bends to be accomplished it would work fine. This type of rivet set can be purchased. However, in tight spaces, like the canopy skin/frames, there's not much room to make the required bends. I haven't found a rivet set that would work - yet. Oh well.

  Feb 24, 2023     Canopy Frame - (2.5 hours)       Category: Canopy+

I started the afternoon by dimpling the left and right canopy side skins before I dimpled all the raining holes in the canopy skin except those for the fans. I also radiused the 3 inches on the outboard side of the left and right notches. Without much instructional guidance I did the radius as close to off scale picture as I could. I then dimpled the left and right 1404 frames and countersunk the font splice. The 'frames' and forward rails were also clecoed together.

  Feb 23, 2023     Canopy Frame - (4.0 hours)       Category: Canopy+

Completed riveting the aft frame handle to the aft canopy frame. Just couldn't squeeze the last two rivets holding the frame splice and had to resort to the pneumatic squeezer. I guess I need to work out more. Moved on to machine countersinking the left and right aft canopy rails for the .025 skin. I made a template so I could check the countersunk holes for accurate depth. I then countersunk the 3 aft holes on the rails for AD3 rivets. I then countersunk the canopy handles for AD3 rivets and also countersunk the left and right forward canopy rails for the skins. I probably had enough leftover metal to remake the vertical stab ribs:-)

  Feb 22, 2023     Canopy Frame - (2.5 hours)       Category: Canopy+

Completely disassembled the forward canopy frame. Assembled and riveted together the canopy handle then clecoed, drilled and riveted the canopy handle to the aft canopy frame. Thanks to my friends Brad and Andrew who just happened to stop and offered to jump right in and help. Much appreciated!

  Feb 21, 2023     Canopy Frame - (2.5 hours)       Category: Canopy+

Completed the right aft canopy frame assembly by riveting the aft canopy rail to the aft canopy rail angle and mated that assembly to the forward canopy frame. Also, the aft frame stiffener was clecoed to the assembly. I final drilled all the #40 holes that were called out. The aft and forward frames are all clecoed together at this point.

  Feb 20, 2023     Canopy Frame - (2.0 hours)       Category: Canopy+

Disassembled the left skin from the aft frame and attached the frame to the forward canopy frame. Finally got everything to fit properly and final drilled the correct holes. Aligned the aft right frame with the fuselage as described and it's also within the 1/32 inch tolerance with the fuselage. Then I set the rivets in the C-01409 rail. They came out perfectly flush, as expected.

  Feb 19, 2023     Canopy Frame - (2.0 hours)       Category: Canopy+

Clecoed the left canopy side skin to the left canopy aft frame thru every open hole. Clecoed the left canopy handle to the assembly, drilled the mounting holes then drilled the pilot hole. Then I removed each cleco, final drilled the hole and replaced the cleco.

  Feb 17, 2023     Canopy Frame - (2.0 hours)       Category: Canopy+

I placed the left aft fuselage frame on the fuselage and fortunately it's within the 1/32 tolerance as stated in the plans - and with very minimal adjustment. The aft canopy flange rivets with the manufactured heads on top and the set of rivets in the countersunk holes on the bottom came out beautiful. I then completed riveting the left aft canopy frame assembly.

  Feb 16, 2023     Canopy Frame - (1.5 hours)       Category: Canopy+

Drilled and countersunk more #40 holes on the aft canopy assembly. (Still needs deburring.)

  Feb 15, 2023     Canopy Frame - (1.0 hour) Category: Canopy+

Worked on the aft canopy frame, countersinking some holes, preparing for more drilling and countersinking.

  Feb 14, 2023     Canopy Frame - (3.0 hours)       Category: Canopy+

Assembled the frame, clecoed the heck out of it, rolled and clecoed the frame closeout then drilled all the necessary holes per page 38-10. The frame rail base angles were measured multiple times and both were 6.8 degrees.

  Feb 13, 2023     Canopy Frame - (2.5 hours)       Category: Canopy+

Work continued on P. 38-09 and although not called out in the plans until P. 38-17, the C-01408 L&R were appropriately countersunk then riveted to the forward and mid frame assemblies. The forward and mid canopy frame splices were matched drilled and riveted in place. Finally, for the day, the frame assemblies were clecoed to the mid and forward fixtures before the entire assembly was clecoed to the canopy skin and checked for fluting gaps. My friend Brad (see the pictures) stoped by and was invaluable as he's better than my clamps at holding things steady while I riveted:-)

  Feb 12, 2023     Canopy Frame - (3.0 hours)       Category: Canopy+

I began disassembling the canopy frame to the point where I clecoed the left and right hinge assemblies to the forward canopy frame so I could rivet them. It looks easy, but like everything else, it's a little more complex than I thought. Once secured so I could begin riveting, I first tried the squeezer, no joy no problem so it's back to the rivet gun. No problem I thought! Wrong. Getting a bucking bar in the tight area was not fun with my fat hand, but it got done. Due to being clumsy the rivet gun slipped off two rivet heads, looks bad, but it's just cosmetic, damn, there goes my perfect riveting record;-) I also riveted the intercostals to the mid frame. Then it was time to cleco the hinge assemblies to the mid frame and the intercostals to the front frame - done. Now it's time to get ready for the Super Bowl!!

  Feb 11, 2023     Canopy Frame - (2.0 hours)       Category: Canopy+

The canopy hinges and the forward canopy rail bases were scuffed and cleaned and primed with SEM self etching primer. After drying, the hinge intercostals were riveted to the hinges and clecoed to the forward and mid canopy frames.

  Jan 31, 2023     Canopy Lock Installation - (2.0 hours)       Category: Canopy+

With the arrival of the final parts, I was able to complete the installation of the canopy latch/lock system. However, I have concern over the hex drive, black finished 10-32 x 9/16 screw holding the long pushrod to the latch handle being a little too short - maybe a 1/4 to 3/8 longer would make me feel a little more comfortable. I will be on the lookout for a longer screw even though this is per the drawing.

  Jan 30, 2023     Canopy Lock Fabrication - (1.0 hour)       Category: Canopy+

I continued to build the canopy frame by clecoing the parts together. At this point, the previously fluted frames are clecoed to the canopy skin along with canopy rails, forward rail bases, canopy frame splices, the hinge assemblies and the intercostals. The canopy closeout frame has also been laid in. The forward and mid rail bases are also clecoed to the assembly. Next I'll have to add more clecoes so the assembly can be double checked for proper fluting, twisting and leveling.

  Jan 29, 2023     Canopy Lock Installation - (.5 hour)       Category: Canopy+

As the Beatles said: "I get by with a little help from my friends." My friend Dean came by and in quick order got all the cotter pins installed. Later, my friend Hart, a recently new RV-10 builder, came by and wanted to learn how to properly bend the cotter pins and bingo, the job was done.

  Jan 28, 2023     Canopy Lock Installation - (2.0 hours)       Category: Canopy+

With the latch brackets and torque rod in place, the latch links were put in place with the MS20392-1C9 pins. I managed to get a few the cotter pins placed in the shafts, but working upside down and with mirrors made it too difficult. (I'm still unable to get inside the fuselage).

  Jan 25, 2023     Canopy Lock Installation - (3.0 hours)       Category: Canopy+

The canopy lock system brackets and the torque tube were screwed in place. The tube had been primed on the inside and upon initial fit, it didn't. I had to grind off about 1/16" to remove any binding. It now moves smoothly with just the right amount of resistance, IMHO.

  Jan 23, 2023     Canopy Lock Fabrication - (2.0 hours) Category: Canopy+

Prepped the canopy lock parts (sanding and cleaning) for painting and painted them flat black. Also, located all the parts for assembly.

  Jan 08, 2023     Parts Fabrication - (1.0 hour)       Category: Canopy+

Yuk, more separating parts, deburring and general mundane tasks, BUT they need to be done.

  Jan 07, 2023     Parts Fabrication - (2.0 hours)       Category: Canopy+

Continued separating parts, deburring and fitting in order to be sure I understand how all these parts makeup the canopy support frame. I hope this is the end of the canopy frame deburring, although I know there are lots of parts that have to have work done on them before painting and assembly. I also located all the flooring and parts covers for future deburring and preparation before painting.

  Jan 05, 2023     Parts Fabrication - (2.0 hours) Category: Canopy+

Boring, but necessary deburring of parts. There sure are a lot of them.

  Jan 04, 2023     Parts Fabrication - (1.5 hours) Category: Canopy+

Nothing exciting, just more deburring of parts for the canopy frame.

  Jan 03, 2023     Parts Fabrication - (1.0 hour)       Category: Canopy+

All the canopy flanges were checked and then fluted as appropriate to make the flanges lie flat. I clecoed the left and right hinge assemblies in preparation for riveting them together.

  Jan 02, 2023     Parts Fabrication - (3.0 hours)       Category: Canopy+

The canopy skin, C-01418 was deburred and dimpled, the C-01402 L&R, C-01403 canopy support flanges were deburred, dimpled and the C-01404 L&R flanges were deburred and dimpled.

  Jan 01, 2023     Parts Fabrication - (1.5 hours)       Category: Canopy+

2023 has arrived. Starting the New Year with more parts fabrication.

  Dec 31, 2022     Parts Fabrication - (3.0 hours)       Category: Canopy+

I continued fabricating canopy parts. These particular pieces are larger and had to be cutout from large formed pieces of aluminum. No big deal but it does require a lot of work to saw them apart and file them smooth. Let me repeat - a lot of filing and smoothing!! Also, there were a few smaller pieces. Looking ahead there are still more pieces to do. Remember, all of these require a lot of deburring too. So much for 2022 and now we get to look forward to 2023!

  Dec 30, 2022     Parts Fabrication - (3.0 hours)       Category: Canopy+

Continued fabricating parts for the canopy assembly. Some of these were fairly routine, the usual cutting them apart, deburring and such; however a few were rather unusual due to their size and shape and took quite a bit longer to separate and 'clean up'. All in all they were slightly challenging and a lot of fun (in an RV sort of way) to complete.

  Dec 29, 2022     Parts Fabrication - (2.0 hours)       Category: Canopy+

Now that the cold snap has eased it's back to the hangar to begin preparing parts for the canopy and window. A number of angle brackets and latch links were prepared, i.e., cut, deburred and edges smoothed out. There are many more small parts yet to do.